Hole abrading tool

ABSTRACT

An abrading tool forms a plurality of grooves in an inner wall surface of a hole having a diameter and a depth, and defining a longitudinal axis, into which an anchor is installed. The tool is configured for mounting to a rotating driver to provide rotational movement to the tool. The tool has a shank having a first end for securing to the rotating driver and a second, free end. The shank has a diameter. A first abrading element is mounted to the shank proximal to the free end. A second abrading element is mounted to the shank spaced from the first abrading element and proximal to the rotating driver. The first and second abrading wheels have a diameter greater than the diameter of the shank. The tool is inserted into the hole and held at an angle relative to the longitudinal axis of the hole. With the rotating driver actuated, the tool is rotated around the hole to form first and second grooves in the inner wall surface of the hole.

BACKGROUND OF THE INVENTION

[0001] The present invention pertains to a tool for abrading holes for anchors. More particularly, the present invention pertains to a tool for abrading holes in concrete and other solid aggregate materials for mechanical-type anchoring systems.

[0002] It is often necessary to install fasteners in aggregate materials such as concrete. Two principle types of anchoring systems are known. In one type of anchoring system, a hole is drilled into the concrete and an anchor is inserted into the hole. The anchor is secured in the concrete by compression using, for example, a wedge that is positioned between an expanding portion of the anchor shank and the wall of the hole. The expanding portion of the anchor urges the wedge outwardly against the inner walls of the hole, thus securing the fastener within the hole.

[0003] Also known are adhesive-type anchoring systems. In such an anchoring system, a hole is drilled into the concrete and an adhesive material is injected into the hole. A fastener, such as a bolt shank is inserted into the adhesive in the hole. When the adhesive cures the anchor is set and secured within the hole.

[0004] Adhesive-type anchoring systems provide a number of benefits over other, known, e.g., wedge-type anchoring systems. For example, a high strength joint is formed with a lesser depth hole than with pure mechanical systems. In addition, adhesive-type systems are less susceptible to slippage (the amount of pulling required to properly set a wedge-type anchor) and are less susceptible to failure due to vibration. Moreover, adhesive-type systems generally withstand higher tension loads than comparably sized and installed conventional mechanical systems.

[0005] One drawback to known adhesive-type anchoring systems is that the strength of the fastener, that is the integrity of the fastener-adhesive-hole joint is contingent upon the integrity of the adhesive-to-aggregate adhesion, as well as the integrity of the aggregate itself. If the aggregate is a smooth or fine grained material, there may be less adhesion between the adhesive and the walls of the hole. This can compromise the integrity of the entire anchoring system joint. Likewise, if the strength of the aggregate material is less than optimal, the walls of the aggregate may degrade, again compromising the integrity of the anchoring system joint.

[0006] Accordingly, there exists a need for improved adhesion between the anchor and the hole into which it is installed. Desirably, such improved adhesion is provided by a tool usable with adhesive-type and non-adhesive type, e.g., wedge-type anchoring systems to enhance the integrity of the overall anchoring system strength. Desirably, such a tool is readily used with minimal increase in labor required for installation. Most desirably, such a tool is used with known and commonly used adhesives and fasteners.

BRIEF SUMMARY OF THE INVENTION

[0007] An abrading tool is used to form a plurality of grooves in an inner wall surface of a hole formed in a material for securing an anchor in the hole. The anchor can be of the adhesive type or non-adhesive type, such as a wedge type anchor. The hole into which the anchor is installed has a diameter and a depth. Typically, these anchors are installed in aggregate materials such as concrete and the like.

[0008] The tool is configured for mounting to a rotating driver, such as a conventional or hammer-type rotary drill. The drill provides rotational movement to the tool.

[0009] The tool includes a shank having a first end for securing to the rotating driver and a second, free end. The shank defines a diameter.

[0010] A first abrading element is mounted to the shank proximal the free end. The first abrading element has a diameter that is greater than the diameter of the shank. A second abrading element is mounted to the shank spaced from the first abrading element and proximal the rotating driver. The second abrading element has a diameter greater than the diameter of the shank.

[0011] In a current embodiment, the abrading elements are abrading wheels, and the diameter of the first abrading wheel is about equal to the diameter of the second abrading wheel.

[0012] In use, the tool is inserted into the hole and held at an angle, i.e., askew, relative to a longitudinal axis of the hole. With the rotating driver actuated, the tool is rotated around the hole to form first and second grooves in the wall of the hole by contact of the abrading wheels with the inner wall of the hole. Optionally, to reduce wear of the shank, a bearing element can be disposed on the shank intermediate the first abrading wheel and the first end.

[0013] The abrading wheels can be permanently affixed to the shank. Alternately, the abrading wheels can be removably mounted to the shank. In the removable configuration, a spacing member, such as a sleeve can be positioned between the first and second abrading wheels. To mount the wheels to the shank, mounting disks can be positioned adjacent the abrading wheels. The mounting disks are rotationally fixedly mounted to the shank and the abrading wheels are mounted to the mounting disks.

[0014] In one configuration for mounting the disks to the shank, the mounting disks include openings formed therein for fitting onto the shank, and the openings are eccentrically disposed relative to a center of the disk. Alternately, the openings are keyed to the shank having a non-circular shape.

[0015] To mount the wheels to the disks, the mounting disks can include pins extending therefrom for receipt in a cooperating opening formed in a respective one of the abrading wheels.

[0016] In a present embodiment, the abrading wheels have a thickness of about ⅛ inch to about ⅜ inch. The wheels are formed from a diamond containing material. Other materials for cutting into material such as concrete aggregates can also be used.

[0017] A method for preparing a hole for installing an associated anchor therein includes the steps of providing a hole for the anchor, the hole defined by a cylindrical inner wall surface and further defining a longitudinal axis. An abrading tool is provided having a shank having an axis. The shank has a first end for securing to a rotating driver and a second, free end. The shank has a diameter.

[0018] A first abrading element is mounted to the shank proximal to the free end. The first abrading element has a diameter greater than the diameter of the shank. A second abrading element is mounted to the shank spaced from the first abrading element and proximal to the rotating driver. The second abrading element has a diameter greater than the diameter of the shank. Preferably, the first and second abrading elements are formed as abrading wheels having about the same diameter.

[0019] The tool is inserted into the hole, and is oriented with its axis askew of the axis of the hole. The tool is rotated about its axis by, for example, a rotating driver. The first and second abrading wheels are contacted with the cylindrical inner wall surface of the hole, and the tool is rotated in a circular pattern to form first and second grooves within hole in the inner wall surface.

[0020] The tool can include mounting disks positioned adjacent the abrading wheels, which disks have a diameter less than the diameter of the abrading wheels. With such a tool, the method can include contacting the mounting disks with the cylindrical inner surface of the hole to stop further groove formation by the abrading wheels.

[0021] These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0022] The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

[0023]FIG. 1 illustrates one embodiment of a hole abrading tool embodying the principles of the present invention, the tool being illustrated mounted to a rotating driver such as the exemplary rotary drill;

[0024]FIG. 2 illustrates the hole abrading tool of FIG. 1 positioned within a hole for use;

[0025]FIG. 3 illustrates another embodiment of the hole abrading tool having replaceable abrading wheels;

[0026]FIG. 4 is a cross-sectional illustration of an adhesive-type anchor installed in a hole that has grooves formed therein as made by the present abrading tool, and illustrates the key and key-way joint formed by the flow of adhesive into the grooves; and

[0027]FIG. 5 is an exploded view of the abrading tool of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

[0028] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.

[0029] Referring now to the figures and in particular to FIG. 1, there is shown one embodiment of a hole abrading tool 10 embodying the principles of the present invention. The tool 10 is mounted to convention rotating driver 12 such as a standard rotary drill or hammer-type drill.

[0030] The tool 10 includes a shaft or shank 14 having a diameter d₁₄. The shank 14 includes a first end 18 for securing to the driver 12 and a second or free end 20. A plurality of abrading elements 16, such as the exemplary abrading wheels are mounted to the shank 14 spaced from one another. Preferably, two abrading wheels 16 are mounted to the shank 14. A first wheel 16 a is mounted to the shank 14 proximal the free end 20 and a second wheel 16 b is mounted to the shank 14 proximal the driver 12.

[0031] The abrading wheels 16 have a diameter d₁₆ that is greater than the diameter d₁₄ of the shank 14. Most preferably, the abrading wheels 16 have about the same diameter d₁₆. In one embodiment, as shown in FIGS. 1 and 2, the abrading wheels 16 are permanently mounted to the shank 14 and are relatively thin as indicated at t₁₆ compared to the length l₁₄ of the shank 14.

[0032] In an alternate embodiment 110, as illustrated in FIGS. 3 and 5, the abrading wheels 116 are mounted to the shank shown generally at 114 by a mechanical fastening arrangement that includes a plurality of sleeves 118, 120 and mounting disks 122, 124 to which the abrading wheels 116 a,b are mounted. A through bolt 126 mounted to a free end 128 of the shank 114 can be used to secure the sleeves 118, 120, disks 122, 124 and wheels 116 a,b to the shank 114. Wheel 16 a is mounted at the free end 128 and wheel 116 b is mounted at the first end 119 of the shank 114.

[0033] To maintain the abrading wheels 116 a,b fixed to the shank 114, so that they do not rotate as the tool 110 rotates, the disks 122, 124 can have keyed openings 130, that is non-circular openings, so that they interferingly fit into corresponding projections 132 on the shank. Alternately, though not shown, the openings in the disks through which the shank is inserted can be off-centered or eccentric.

[0034] To secure the wheels 116 a,b to the disks 122, 124, a projection 134 can extend from a side of each disk 122, 124 that fits into an opening or hole 136 in corresponding abrading wheel 116 a,b thus locking the wheels 116 a,b to the disks 122, 124. The length l₁₁₈ of sleeve 118 can be varied to provide a desired spacing between the wheels 116 a,b and overall tool 110 length for any required application or use.

[0035] The disks 122, 124 can also be configured to provide a grooving stop for the tool 110. That is, the disks 122, 124 can be configured so that as the wheels 116 a,b grind or cut into the cylindrical inner wall surface S of the hole H (as will be described in more detail below), contact of the disks 122, 124 with the surface S prevents further penetration of the abrading wheels 116 a, b into the surface S.

[0036] Optionally, in either embodiment, a bearing-like sleeve as indicated at 22 in FIG. 2 and 125 in FIG. 3, can be positioned on the shank 14, 114 at about the location at which the shank 14, 114 contacts the edge E of the hole H at the upper surface U. The shank 14, 114 rotates within the sleeve 22, 125. To this end, the shank 14, 114 is prevented from contacting the aggregate material M and is thus less susceptible to wear. In that this part can be fabricated as a sacrificial member, it can be fabricated from any commonly available material, and can be replaced as needed.

[0037] The abrading 10, 110 tool is used for abrading the inner wall surface S of a hole H that has been drilled into an aggregate material M for securing a fastener or anchor F therein. Referring again to FIG. 1, in use, the abrading tool 10 is mounted to the driver 12. The tool 10 is inserted into the hole H and is leaned or tilted to one side of the hole H so that the shank 14 (or preferably the bearing sleeve 22) contacts the edge E of the hole H at the upper surface U. That is, the tool 10 is held with the longitudinal axis A₁₀ askew relative to the longitudinal axis A_(H) of the hole H such that the abrading wheels 16 contact the inner wall surface S in opposing relation to one another, i.e., at 180 degrees from one another.

[0038] The driver 12 is then actuated and is rotated around the hole H so that each of the abrading wheels 16 a,b, 116 a,b comes into full, circumferential contact with the inner wall surface S. In this manner, the abrading tool 10, 110 creates a pair of circular undercuts or grooves G in the inner wall surface S at each of the abrading wheels 16 a,b, 116 a,b.

[0039] As shown in the figures, current embodiments of the tool 10, 110 include two abrading wheels 16 a,b, 116 a,b spaced from one another. Each of the wheels 16 a,b 116 a,b has a diameter d₁₆, d₁₁₆ that is about the same diameter as a drill bit that is used to form the hole H. That is, the diameter d₁₆, d₁₁₆ of the abrading wheels 16, 116 is such that the tool 10, 110 fits within the hole without significant space between the peripheries of the wheels 16, 116 and the inner wall surface S.

[0040] As set forth above, the tool 10, 110 can be used for abrading holes H for both adhesive-type and non-adhesive-type anchoring systems. In one anticipated use in which the anchors are installed in adhesive filled holes, as illustrated in FIG. 4, the wheels 116 a,b are relatively thin, that is about ⅛ inch to about ¼ inch in thickness, for cutting the grooves G into the inner wall surface S. In another anticipated use in which the abrading tool 10, 110 is used to cut grooves G into wall surfaces S in which non-adhesive-type anchors are installed in the holes H, the abrading wheels 16, 116 can be larger to cut larger grooves G into the wall surface S.

[0041] In the second type of installation (not shown) in which non-adhesive anchors are installed in the grooved or abraded holes H, an expanding mechanical member can be positioned on the shank of the anchor. Such an expanding member can be configured to fit into the groove G to provide an interference fit with the groove G. That is, at least a portion of the expanding mechanical member expands into the groove G, beyond the inner circumference of the hole wall. Thus, pull-out of the anchor is interfered with by the expanded mechanical member. In such an arrangement, it is anticipated that the groove will have a width of at least about ¼ inch to about ⅜ inch to provide sufficient space for expansion of the expanding mechanical member. These types of anchors and their use will be well recognized by those skilled in the art, and are within the scope of the present invention.

[0042] In the first type of application in which an adhesive material 30 is injected into the hole H, following the cutting of grooves G and after injection of the adhesive 30, a fastener or anchor F is inserted into the adhesive material, and the adhesive is allowed to cure. The anchor is then ready for use. In the second application in which a non-adhesive, expanding mechanical member-type anchor is used, after forming the grooves G, the anchor is inserted into the hole and the expanding member is expanded to ready the anchor for use.

[0043] It has been found that in the adhesive-type joint use, after the adhesive cures, the tensile performance of adhesive-type anchors installed using the present abrading tool increases between about 20 and 100 percent over adhesive-type anchoring systems installed directly into straight walled holes. It has been observed that the grooves G cut into the inner wall surface S form key-ways 32 into which the adhesive material 30 flows to form a key-like mechanical lock, as indicated at 34, between the adhesive material 30 and the wall surface S and grooves G. This increased performance enhances the tensile characteristics of such systems in all applications, and has been found to be critical in certain applications.

[0044] As will be recognized by those skilled in the art, there are times that a certain, minimum hole depth cannot be achieved for anchor installation. Also as will be recognized by those skilled in the art, the depth D of the hole H into which an anchoring system is installed is critical to the strength of the joint (e.g., tensile or pull-out strength). When the minimum hole depth cannot be met, the overall fastener joint integrity can be severely compromised.

[0045] Using the present system in which an abrading tool 10, 110 is used to abrade or cut grooves G into the inner wall surface S of the hole H, increased overall joint performance is enhanced and critical tensile requirements are more readily met. This is due to the key 34 and key-way 32 like configuration formed by the cured adhesive 30 in the grooves G formed in the wall surface S.

[0046] Those skilled in the art will recognize the various types of abrading materials that can be used for the present abrading tool. In a present tool, the abrading wheels 16, 116 are manufactured from diamond-containing materials. These materials, as well as others will be recognized by those skilled in the art and are within the scope and spirit of the present invention.

[0047] In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

[0048] From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. 

What is claimed is:
 1. An abrading tool for forming a plurality of grooves in an inner wall surface of a hole formed in a material, the hole having a diameter and a depth defining a longitudinal axis, the tool being configured for mounting to a rotating driver to provide rotational movement to the tool, the tool comprising: a shank having a first end for securing to the rotating driver and a second, free end, the shank having a diameter; a first abrading element mounted to the shank proximal to the free end, the first abrading element having a diameter greater than the diameter of the shank; and a second abrading element mounted to the shank spaced from the first abrading element and proximal to the rotating driver, the second abrading element having a diameter greater than the diameter of the shank, wherein the tool is inserted into the hole and held at an angle relative to the longitudinal axis of the hole, and with the rotating driver actuated, the tool is rotated around the hole to form first and second grooves in the inner wall surface of the hole by contact of the abrading elements with the inner wall surface of the hole.
 2. The abrading tool in accordance with claim 1 wherein the abrading elements are abrading wheels.
 3. The abrading tool in accordance with claim 1 including a bearing element disposed on the shank intermediate the first abrading element and the first end.
 4. The abrading tool in accordance with claim 1 wherein the abrading elements are permanently affixed to the shank.
 5. The abrading tool in accordance with claim 1 wherein the diameter of the first abrading element is about equal to the diameter of the second abrading element.
 6. The abrading tool in accordance with claim 1 wherein each of the abrading elements has a thickness of about ⅛ inch to about ⅜ inch.
 7. The abrading tool in accordance with claim 1 wherein the abrading elements are removably mounted to the shank.
 8. The abrading tool in accordance with claim 7 including a spacing member positioned between the first and second abrading elements.
 9. The abrading tool in accordance with claim 8 wherein the spacing member is a sleeve positioned about the shank.
 10. The abrading tool in accordance with claim 7 including mounting disks positioned adjacent the abrading elements.
 11. The abrading tool in accordance with claim 10 wherein the mounting disks are rotationally fixedly mounted to the shank and the abrading elements are mounted to the mounting disks.
 12. The abrading tool in accordance with claim 11 wherein the mounting disks include pins extending therefrom for receipt in a cooperating opening formed in a respective one of the abrading elements.
 13. The abrading tool in accordance with claim 11 wherein the mounting disks include openings formed therein for carriage by the shank, and wherein the openings are eccentrically disposed relative to a center of the disk.
 14. The abrading tool in accordance with claim 1 wherein the abrading elements are formed from a diamond containing material.
 15. A method for preparing a hole for installing an associated anchor therein, comprising: providing a hole for the anchor, the hole defined by a cylindrical inner wall surface and defining a longitudinal axis; providing an abrading tool having a shank having an axis, the shank having a first end for securing to a rotating driver and a second, free end, the shank having a diameter, a first abrading element mounted to the shank proximal to the free end, the first abrading element having a diameter greater than the diameter of the shank, and a second abrading element mounted to the shank spaced from the first abrading element and proximal to the rotating driver, the second abrading element having a diameter greater than the diameter of the shank; inserting the abrading tool into the hole; orienting the tool with its axis askew of the longitudinal axis of the hole; rotating the tool about its axis; and contacting the first and second abrading elements with the cylindrical inner wall surface of the hole, in a circular pattern, to form first and second grooves in the inner cylindrical wall surface.
 16. The method in accordance with claim 15 wherein the tool includes mounting disks positioned adjacent the abrading elements, the disks having a diameter less than the diameter of the abrading elements, and wherein the method further includes the step of contacting the mounting disks with the cylindrical inner wall surface of the hole to stop further groove formation by the abrading elements.
 17. The method in accordance with claim 15 wherein the abrading elements are abrading wheels. 